Chevrolet 1500 SAFETY

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1 Chevrolet 1500 REAR BUMPER INSTALLATION INSTRUCTIONS SAFETY Know safety, no injury. Know injury, no safety. ~Author Unknown READ ALL SAFETY INSTRUCTIONS BEFORE INSTALLATION o o o o o FOLLOW ALL INSTRUCTIONS FOR PROPER ASSEMBLY WEAR APPROPRIATE EYE PROTECTION EXERCISE CARE WHEN LIFTING COMPONENTS USE APPROPRIATE TORQUE FOR BOLTS BLUE THREAD LOCKING COMPOUND IS RECOMMENDED ON ALL BOLTS o SUGGESTED TORQUE VALUES FOR STEEL GRADE SAE 5 BOLTS BOLT DIAMETER (INCH) TREADS PER INCH TORQUE (POUND FEET) 1/ / / / ½ / / ¾ / Rev 00 Page 1

2 I. PARTS LIST QUANTITY PART NUMBER DESCRIPTION / CHEVY 1500/ CHEVY 1500 W/PARK ASSIST 1 60P PAINTED PASS FRAME MOUNT WELDMENT 1 60P PAINTED DRIVER FRAME MOUNT WELDMENT 1 60K HARDWARE PACKAGE # GROMMET FOR 4 RD SEALED LIGHT BACK UP LIGHT SEALED, 4 RD BACK UP LIGHT PIGTAIL LICENSE PLATE LIGHT /8 REAR PARK ASSIST GROMMET MALE BULLET CONN LICENSE PLATE MOUNTING KIT II. TOOL LIST mm socket 2. 21mm socket 3. 15mm socket 4. ¾ socket 5. ¾ wrench Rev 00 Page 2

3 Chevrolet 1500 Rear Bumper III. REMOVAL OF OEM BUMPER 1. Unplug OEM license plate lights and secure out of the way. 2. (Vehicle with rear park sensors) make sure to unplug the wiring harness and secure out of the way. 3. Using 18mm socket remove two nuts from a bolt strip that holds the bumper to the frame. See figure 1. (both sides) Figure 1 Rev 00 Page 3

4 4. Remove bolt strip (both sides). See Figure 2. Figure 2 5. Using 21mm socket remove lower bolt holding bumper to frame mount. See figure 3 and figure 4.(both sides) Figure 3 Rev 00 Page 4

5 Figure 4 6. Using 15mm socket remove one bolt per side holding bumper to frame. See Figure 5. Figure 5 Rev 00 Page 5

6 7. Using 21mm remove two bolts holding bumper to OEM receiver hitch. See figure 6 and figure 7 Figure 6 Figure 7. Rev 00 Page 6

7 8. Carefully remove OEM bumper and place out of the way. 9. (Vehicles with rear park assist) From OEM bumper remove rear park assist sensors and wiring harness. (These will be placed into Hammerhead bumper) 10. From OEM bumper remove the spare tire let down by depressing tabs on the O-Ring holding on plastic lock from the back side of OEM bumper and pulling the spare tire lock through the bumper. See Figure 8. Spare Tire Lock O-Ring Figure 8 Rev 00 Page 7

8 11. Remove the trailer plug adapter from OEM bumper. ( In some cases this will be a dummy plug that hides the trailer plug hole). See figure 9 and figure 10. Trailer plug Figure 9 Figure 10 Rev 00 Page 8

9 IV. INSTALLATION OF HAMMERHEAD BUMPER 1. Place OEM trailer plug into HammerHead bumper. Do this by inserting into the slot shown in figure 11 and twisting till it locks in place. Figure Insert OEM spare tire lock into HammerHead bumper by running the spare tire lock plastic piece through the front of the bumper hole and capturing it by putting the O-Ring removed in step 10 of uninstallation around it. See Figure 12 Spare Tire Lock O-ring Figure 12 Rev 00 Page 9

10 3. (Vehicles with park assist sensors) EXTREME CAUTION!! Install OEM rear park assist sensors into HammerHead bumper. Use a lubricating fluid (Soapy water works) to minimize friction while inserting sensors into grommets. Take care not to twist the sensors while inserting as this will damage the sensor. The sensor needs to be positioned and tested to ensure the sensor is in the correct location. 4. Align frame mounts to the inside of frame mount as shown in figure 13, figure 14 and figure 15. Figure 13 Rev 00 Page 10

11 Figure 14 Figure 15 Rev 00 Page 11

12 5. Using bolt strip and the bolt strip nuts hand tighten nuts. See Figure 16. Figure 16: Outer view of driver side frame mount 6. Hand tighten bolt single bolt from Hardware kit #16 Figure 17. Rev 00 Page 12

13 7. Align HammerHead bumper to frame mounts and using 8 of the ½ long bolts from hardware kit #16 hand tighten the bumper to the frame mounts. 8. Using the remaining two bolts (1/ long bolts) from hardware kit #16 hand tighten the bolts though the OEM receiver hitch into the bottom plate of the HammerHead bumper. 9. Position HammerHead bumper to the desired location on vehicle. 10. Using a ¾ wrench and ¾ socket tighten the two bolts from hardware kit # 16 from install step Using a ¾ wrench and ¾ socket tighten the eight bolts from hardware kit #16 from install step Using a 18mm socket tighten the two nuts for the bolt strip from install step 5. (both sides) 13. Using a 15mm socket tighten single bolt from install step Wire license plate lights into HammerHead bumper. Rev 00 Page 13

14 CONGRATULATIONS!! Rev 00 Page 14

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